110916 reglo wall-man technical manual rev 7_layoutrev_28 04

WALL-MAN®

Pneumatic Access Platform

TECHNICAL MANUALRev. 7 - 110916

Reglo AS WALL-MAN – Technical manual

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Reglo ASAndebu NæringsparkNO-3158 AndebuNorwayTel.: +47 / 33 43 02 80Fax.: +47 / 33 43 02 81E-mail: [email protected] Web: www.reglo.no


TABLE OF CONTENT

TABLE OF CONTENT...................................................................................................................................... 2

1. INTRODUCTION................................................................................................................................. 4

1.1 General................................................................................................................................................ 41.2 Purpose of manual............................................................................................................................... 41.3 Reference documents.......................................................................................................................... 41.4 Contact address................................................................................................................................... 51.5 Marking................................................................................................................................................ 51.6 Symbols and conventions.................................................................................................................... 61.6.1 As used in manual............................................................................................................................... 61.6.2 As used on the equipment...................................................................................................................61.7 Safety notes......................................................................................................................................... 71.8 Abbreviations....................................................................................................................................... 81.8.1 Interfaces............................................................................................................................................. 8

2. MAIN DATA......................................................................................................................................... 9

2.1 Product range...................................................................................................................................... 92.2 Standard specifications........................................................................................................................ 92.3 Dimensions.......................................................................................................................................... 9

3. SAFETY FEATURES......................................................................................................................... 10

4. TECHNICAL DESCRIPTION.............................................................................................................11

4.1 Overview and purpose....................................................................................................................... 114.1.1 Assembly........................................................................................................................................... 114.1.2 Control Panel..................................................................................................................................... 124.1.3 Air supply........................................................................................................................................... 124.1.4 Emergency lowering lever.................................................................................................................. 13

5. HANDLING AND STORAGE.............................................................................................................14

5.1 Handling and transport....................................................................................................................... 145.1.1 Transport seals ................................................................................................................................. 145.1.2 Pallets ............................................................................................................................................... 155.2 Storage.............................................................................................................................................. 15

6. OPERATION...................................................................................................................................... 16

6.1 Overview............................................................................................................................................ 166.2 Start................................................................................................................................................... 176.2.1 Daily checks before start-up...............................................................................................................176.2.2 Left and right movement....................................................................................................................186.2.3 In and out movement......................................................................................................................... 206.2.4 Up and down movement.................................................................................................................... 216.2.5 Emergency lowering lever.................................................................................................................. 226.2.6 Lift chain safety device....................................................................................................................... 236.3 Practical exercises............................................................................................................................. 246.3.1 Exercise 1.......................................................................................................................................... 246.3.2 Exercise 2.......................................................................................................................................... 246.3.3 Exercise 3.......................................................................................................................................... 246.3.4 Exercise 4.......................................................................................................................................... 246.3.5 Passing a pivoted rail (if applicable)...................................................................................................25

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7. MAINTENANCE................................................................................................................................. 26

7.1 Maintenance programme................................................................................................................... 267.1.1 Handling leaks................................................................................................................................... 287.1.2 Measuring air pressure...................................................................................................................... 287.2 Trouble shooting................................................................................................................................ 297.3 Replacements and adjustments.........................................................................................................307.3.1 Replacing the nylon rollers (WM-IO8 / WM-UD17)............................................................................307.3.2 Replacement of the air motor.............................................................................................................307.3.3 Adjustment of spring tension of the hose reels..................................................................................31

TABLE OF FIGURES

Figure 1-1 Marking........................................................................................................................................... 5Figure 1-2 Interfaces......................................................................................................................................... 8Figure 3-1 Safety features.............................................................................................................................. 10Figure 4-1 WALL-MAN main parts..................................................................................................................11Figure 4-2 Control panel................................................................................................................................. 12Figure 4-3 Control panel................................................................................................................................. 12Figure 4-4 Air inlet for tools or breathing air and lockable main valve.............................................................12Figure 4-5 Emergency lowering lever next to the mast...................................................................................13Figure 5-1 WALL-MAN with transport seals...................................................................................................14Figure 5-2 Packing approval........................................................................................................................... 15Figure 5-3 Packing Reglo pallet...................................................................................................................... 15Figure 6-1 The air inlet in open and locked positions......................................................................................17Figure 6-2 Left and right manoeuvring............................................................................................................18Figure 6-3 Foot pedal..................................................................................................................................... 19Figure 6-4 In and out manoeuvring.................................................................................................................20Figure 6-5 Up and down manoeuvring............................................................................................................21Figure 6-6 Emergency lowering lever.............................................................................................................22Figure 6-7 Chain slack valve (behind panel)...................................................................................................23Figure 6-8 Pivoted rail..................................................................................................................................... 25

APPENDIX

A SPARE PART LIST

B DRAWINGS AND DATA SHEETS

C WARRANTY CERTIFICATE

D APPROVALS

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1. INTRODUCTION 1.1 GENERAL

Congratulations with your new WALL-MAN.

The WALL-MAN is a pneumatic access platform which replaces ladders, scaffolding, etc. and thus creates a safe and effective working place. At the top the WALL-MAN hangs and runs on rails mounted on the walls of the spray booth /paint shop. The lower end of the WALL-MAN has wheels which only touch the wall, not the floor.

WALL-MAN ensures mobility and manoeuvrability from the cage in any height. Controls in the cage are for left / right, in / out and up/down movements. The up/down movement is done by means of two powerful double-acting air cylinders.

Please verify that you have received everything according to the packing list.

1.2 PURPOSE OF MANUAL

This manual provides the user with the necessary instructions to operate and maintain the WALL-MAN pneumatic access platform as supplied by Reglo as (Reglo).

This manual is provided for qualified and trained personnel.

It is important that all personnel concerned read this manual. The Equipment is to be handled in accordance with the instructions given in this manual or other referenced documentation.

If problems occur beyond the scope of this manual, please contact Reglo for assistance.

Reference documents

Always use the latest revision of a document.

The following documents are referenced and can be found in Appendix:

Reference Title

A Spare part list

B-1 Product Data Sheet

B-2 GA drawing

B-3 Pneumatic plan

B-4 Location plan

C Warranty certificate

D-1 EC declaration of conformity

D-2 CE certificate

D-3 UL certificate (if applicable)

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1.3 CONTACT ADDRESS

Reglo AS

Andebu Næringspark

N-3158 Andebu

Norway

Tel.: +47 33 43 02 80

Fax: +47 33 43 02 81

E-mail: [email protected]

Web site: www.reglo.no

1.4 MARKING

The identification label for WALL-MAN is attached to the operation panel.

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http://www.reglo.no/

mailto:[email protected]


1.5 SYMBOLS AND CONVENTIONS

1.5.1 As used in manual

The following words and symbols found throughout this manual mark special messages to alert the operator of specific information concerning of the PERSONNEL, the EQUIPMENT or the PROCESS.

Text set off in this manner provides warning notice that failure to follow these directions in this warning can result in bodily harm or loss of life and/or extensive damage to equipment.

Text set off in this manner provides warning notice that failure to follow these directions in this CAUTION can result in damage to equipment.

Text set off in this manner present clarifying information or specific instructions pertinent to the immediate instruction.

Text set off is this manner is used to identify any possible environmental impact of actions taken or equipment/material used.

1.5.2 As used on the equipment

The following signs and symbols are used on the WALL-MAN:

Sign or symbol Description

ATEX Classification

Maximum working pressure

Type sign

Warning sign1 Read manual before use2 Always wear safety harness

Emergency lowering sign

Emergency in sign (if applicable)

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Figure 1-1 Marking


1.6 SAFETY NOTES

Read and understand this manual before installing and using the WALL-MAN.

Follow all safety instructions.

Never use an item of equipment that is damaged or has defective parts.

Protective clothing and safety glasses must be worn whenever there is a possibility of contact with chemical substances.

Ensure that rails are securely fastened to the wall.

Ensure the end stoppers are intact and securely fastened.

Keep the access doors closed while using the WALL-MAN.

Keep the cage floor dry and clean while using the platform.

Do not climb on the cage or mast.

Do not use ladders, chairs, etc. inside the cage.

Use only original spare parts.

Never use the WALL-MAN as a jack, crane or similar.

Never exceed maximum payload.

The WALL-MAN may only be used by authorised personnel that have been trained in operation. Always use the WALL-MAN carefully and responsibly.

Government and company health and safety regulations must be obeyed at all times.

Warranty claims are only valid if original spare parts are used. (Refer to current warranty regulations.)

It is the operator’s responsibility to identify possible hazardous situations and to take the necessary precautions in order to avoid serious accidents to personnel and equipment.

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1.7 ABBREVIATIONS

Abbreviation Description

GA General arrangement

Reglo Reglo AS

Rev. Revision

SWL Safe working load

WM WALL-MAN

1.7.1 Interfaces

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2. MAIN DATA

2.1 PRODUCT RANGE

WALL-MAN Distance from wall 1) Cage size 2) Door Miscellaneous

Model Axis Min Max Width Depth Width1300/100 3D 1285 2585 900 820 5201200/100 3D 1235 2435 900 820 5201100/100 3D 1185 2285 900 820 5201000/100 3D 1135 2135 900 820 520900/100 3D 1085 1985 900 770 470800/100 3D 1035 1835 900 720 470700/100 3D 985 1685 900 670 420600/100 3D 935 1535 900 620 370

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Only general interfaces shown. Please refer to GA drawing for project specific details.

For technical description refer to section 4.1.3.

Figure 1-2 Interfaces

Air inlet and main control valve.

Compressed air interface reel to WALL-MAN.

Compressed air interface on wall to reel.


500/100 3D 885 1385 900 570 420 One door only400/100 3D 835 1235 900 520 370 One door only

1) Offset possible up to 250 mm. Greater reach possible with brackets.2) Cage width can be extended up to 1200 mm.

Fixing height for all standard models is 4170 mm – but can be extended up to 5420 mm. Lifting height (cage floor) for all standard models is 3275 mm – but can be extended up to 4525 mm.

2D models available on request.

2.2 STANDARD SPECIFICATIONS

For specifications according to order please refer to Appendix.

Item Data

Max payload 150 kg

Lifting height 3275 mm (up to 4525 mm)

Fixing height 4170 mm (up to 5420 mm)

Maximum lifting speed 100 to 120 mm/second

Maximum driving speed Approx. 50 m/minute

Net weight Approx. 280 kg

Forces applied to wall at upper rail:Horizontally Approx. 120 kgVertically Approx. 420 kg

Forces applied to wall at lower support wheels:Horizontally Approx. 120 kgVertically 0 kg

Maximum noise level in use <85dB(A)

Air supply Nederman 893, 889, 884

Pressure: Min./max. 6/8 bar

Recommended 7 bar

Air consumption 350 litre/minute

Hose lengths 10, 15, 20 or 30 m

Telescopic movement 400-1300 mm

2.3 DIMENSIONS

Refer to GA drawing listed in Appendix for details.

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3. SAFETY FEATURES

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Figure 3-3 Safety features

Chain protection panels

Self closing hinges

Self closing latches.

Emergency lowering.

Non slip floor in cage

Signal horn.

Hook for safety harness.

In/out

Pressurised cylinders for steady positioning

Loss of air pressure allows manual movement

Telescoping cage

Up/down Safety flow restrictors

in case of air loss. Loose chain stop /

chain straighter. Safety factor 11 on

lifting chains. Safety chain on air

supply. Chain slack protection

Cage in upper position

Sideways

WALL-MAN on rails

Brake system for steady positioning

Guide rollers to avoid threshold (doors <80cm)

Rubber stoppers in rail.

Safety hook in rail.

Loss of air pressure allows manual movement.


4. TECHNICAL DESCRIPTION4.1 OVERVIEW AND PURPOSE

WALL-MAN ensures mobility and manoeuvrability from the cage in any height. Controls in the cage are for left/right, in/out and up/down movements. The up/down movement is done by means of two powerful double-acting air cylinders. The in/out movement is done by two Lintra cylinders and the sideways movement is run by the air motor.

The WALL-MAN is hanging and running in the top rail and is absolutely stable, it cannot tip over. The upper wheels are trapped in the rail so that the WALL-MAN can only be lifted out of the rail at the installation openings which are locked during operation. Should a wheel or shaft break, a safety hook keeps the WALL-MAN in the rail. The lower rail is for guidance and support only.

4.1.1 Assembly

1 Upper wheel non driving 7 Upper rail 13 Lower support wheels2 G-Profile rail bracket 8 Mast 14 Upper wheel driving3 Chain protection panels 9 Track for cableway 15 Air motor4 Sprocket wheel on lifting cylinder 10 Cableway 16 Cage5 Chain for lifting 11 Main lifting cylinder 17 Lintra horizontal cylinder6 Hose reel 12 Operator’s panel (inside the cage) 18 Control lever/emergency lowering

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4

5

7

8

9

15

14

16

10

1

12

13

2

11

3

6

Figure 4-4 WALL-MAN main parts

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4.1.2Control Panel

1 Protection bar (hand support)2 Lever for in/out movement3 Lever for up/down movement4 Lever for left/right movement5 Warning signal horn6 Air inlet7 Main control valve – lockable

4.1.3 Air supply

A compressed air outlet is provided in the cage for spray gun or other tools. The compressed air can be filtered in the cage to be used as breathing air.

Figure 4-6 Control panel Figure 4-7 Air inlet for tools or breathing air and lockable main valve

4.1.4 Emergency lowering lever

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6

12

3

4

5

Figure 4-5 Control panel


The cage can also be operated from the emergency lowering lever. This makes it possible to perform emergency lowering or to “park” the cage in the upper position to create maximum space.

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Figure 4-8 Emergency lowering lever next to the mast


5. HANDLING AND STORAGE

5.1 HANDLING AND TRANSPORT

Handle the platform and its parts carefully; pneumatic parts can get damaged!

Use only proper tools for handling. Use only tested and certified lifting equipment.

Transport the WALL-MAN on a pallet, suitably strapped down to prevent movement.

Transport seals are only to be removed after the WALL-MAN is installed in the rails.

Wooden packing materials to be heat treated and debarked

5.1.1 Transport seals

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Figure 5-9 WALL-MAN with transport seals


5.1.2 Pallets

Our production unit, Andebu Mekanikk AS, has received approval according to International Standard for Packing Materials:

ISPM 15:

NO-SLT

935 437 903

HT DB

HT = Heat Treated DB = Debarked

5.1.3 Scope of delivery

The WALL-MAN is delivered in the following parts:

Main mast with cages

Upper rail (four meter lengths)

G-brackets for upper rail mounting

Rubber end stoppers

Technical Manual and Installation Manual (if not sent in advance)

Other items (hose reel, hose reel brackets, etc.) as required. Normally packedinside the cage.

5.2 STORAGE

If the WALL-MAN is to be stored for an extended period, an indoor storage area is recommended. If stored outdoor the WALL-MAN must be protected against rain, snow, sea-spray or excessive dust.

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Figure 5-11 Packing approval Figure 5-10 Packing Reglo pallet


6. OPERATION

6.1 OVERVIEW

Never exceed maximum payload.

The operator must use safety harness at all times.

WALL-MAN may only be used by authorised personnel who have been trained in the operation.

Ensure that personnel are not moving around in the operating area of the WALL-MAN . Watch out for people entering the booth/hall.

Never drive at full speed against the rubber end stoppers.

Never run the platform across a pivoted rail without checking the pivot first.

Keep the WALL-MAN free from debris and such like.

Keep the doors closed at all times when the WALL-MAN is used.

Be careful when the air hose is fully extended. The WALL-MAN operating range is limited to the air hose length from the air connection point.

Avoid long hoses when using tools connected to the outlet in the cage. Hoses hanging out of the cage can catch on the WALL-MAN and cause defects.

In case of loss of compressed air (compressor failure, air supply break down, punctured hose), the WALL-MAN remains in its current position. All movements are disabled, only lowering remains possible. In case of loss of compressed air and the cage is above an obstacle, the platform can be pushed sideways and the cage can be moved in manually.

The WALL-MAN is driven by compressed air which is a flexible substance. This might lead to a delayed response. However, with a little practice, WALL-MAN can be steered very precisely.

WALL-MAN can be moved in the following ways:

Driving left or right along the wall.

Telescoping the cage in and out.

Raising and lowering the cage.

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6.2 START

The WALL-MAN is designed with safety in mind, but as with any mechanical lifting device, there are potential dangers caused by misuse or negligent use.

Always use WALL-MAN carefully and responsibly.

WALL-MAN is turned on and off with the lockable main control valve on the control panel.

6.2.1 Daily checks before start-up

The following checks must be done daily before start-up:

Check for: Action

Defects Visually check for defects such as broken parts, loose items, etc.

Debris Keep the WALL-MAN free from debris, dirt and other rubbish.

Leaks Listen for the hissing sound of air leaking.

Obstacles Check that there are no obstacles in the operating area.

Personnel Check that no unauthorised personnel are in the operating area.

Doors Check that the door closes and locks properly.

Safety Hook Check that the safety hook is fixed correctly to the cage.

Compressed air Verify that minimum 6 bar is available.

Breathing air If breathing mask is used, check all necessary parts according to

Controls Operate the WALL-MAN in all 3 directions.

If one of the above mentioned checks creates a problem, do not use the WALL-MAN. Any defects must be reported immediately.

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Figure 6-12 The air inlet in open and locked positions


6.2.2 Left and right movement

Operate the WALL-MAN sideways by means of the right hand lever on the control panel.

In case of loss of air pressure, it is still possible to manually move the WALL-MAN.

If the joystick is not activated it returns to neutral.

For short and precise manoeuvring, operate the joystick in short movements.

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Air motor

Figure 6-13 Left and right manoeuvring


6.2.2.1 Foot pedal (if applicable)

A WALL-MAN fitted with a foot pedal can be manoeuvred sideways on the rail by stepping on the left and the right side of the foot pedal as indicated.

.

WALL-MAN can also be fitted with foot pedals for up/down or/and in/out movement.

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Figure 6-14 Foot pedal


6.2.3 In and out movement

Move the WALL-MAN in and out by means of the left hand lever on the control panel.

Figure 6-15 In and out manoeuvring

In case of loss of air pressure, it is still possible to manually move the WALL-MAN.



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Lintra cylinders


6.2.4 Up and down movement

Operate the up and down movement of the WALL-MAN by means of the centre hand lever on the control panel.

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Lifting cylinders with chain (behind protection panels)


In case of loss of air pressure, it is still possible to safely lower the WALL-MAN.



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Figure 6-16 Up and down manoeuvring


6.2.5 Emergency lowering lever

In the event that air pressure or supply is lost when the cage is raised, an emergency lowering lever, located next to the mast, will permit the lowering of the cage.

If the emergency is due to loss of air pressure the cage will be lowered after a short delay.

The lever can also be used to raise and lower the cage during normal operation.

Do not park the platforms in upper position over longer time without supervision.

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Figure 6-17 Emergency lowering lever


6.2.6 Lift chain safety device

If the cage is lowered onto an obstacle, the lifting chain may slacken and an integrated safety device will raise the cylinder rods until all chains are tightened. While this happens, the lifting control lever in the cage is disabled for downward movement (can be lifted upwards).

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Figure 6-18 Chain slack valve (behind panel)


6.3 PRACTICAL EXERCISES

The following practical exercises are to be performed by all operators before using the equipment for the first time.

6.3.1 Exercise 1

Identify the following parts: 1. Shut off valve.

2. Emergency down valve.

3. Control panel.

4. Air outlet for tools.

5. Safety hook for harness.

6.3.2 Exercise 2

Perform Daily checks Enter the cage and conduct the daily checks according to section 6.2.

6.3.3 Exercise 3

ALWAYS USE SAFETY HARNESS WHEN OPERATING THE WALL-MAN

Use the controls in the following order:

1. Raise the cage to full height.

2. Lower the cage completely.

3. Move left and right.

4. Extend cage fully.

5. Raise and lower cage, and then move left or right.

6. Operate several control levers at the same time..

The speed may vary due to variable air consumption.

6.3.4 Exercise 4

Simulate pressure loss: 1. Raise the cage.

2. Close air supply with main control valve.

3. Try raising/lowering or moving the WALL-MAN with the controls.

4. Activate the emergency lowering lever and lower the cage.

If the emergency is due to loss of air pressure the cage will be lowered after a short delay (approx. 10 seconds).

5. Re-open the main control valve

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6.3.5 Passing a pivoted rail (if applicable)

To open:

1. Pull chain cord (1) and open pivot (2)

2. Secure chain cord in locking device (3)

3. Check that all guide rail locks (4 and 5) have engaged properly and prevent the WALL-MAN from driving out of the rail.

To close:

1. Release chain cord (1) and close pivot (2)

2. Check that the pivot has closed properly and that there is no “step” in the rail.

Can be delivered pneumatically operated.

Figure 6-19 Pivoted rail

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2

2

1

1

3

5

3

4

No ”step”


7. MAINTENANCE

Dispose of used rags, etc. according to local legislation.

7.1 MAINTENANCE PROGRAMME

The WALL-MAN requires minimal service and maintenance. However due to environment and conditions where it is used, it is recommended that the following routines are carried out.

Daily: Action:

Check for defects Visually check for defects such as broken parts, loose items, etc.

Check for debris Keep the WALL-MAN free from debris, dirt and other rubbish.

Check for leaks Listen for the hissing sound of air leaking.

Check for obstacles Check that there are no obstacles in the operating area.

Check for personnel Check that no unauthorised personnel are in the operating area.

Check doors Check that the door closes and locks properly.

Check for safety hook Check that the safety hook is fixed correctly to the cage.

Check compressed air Verify that minimum 6 bar is available.

Check breathing airIf breathing mask is used, check all necessary parts according to manufacturer’s instructions

Check controls Operate the WALL-MAN in all 3 directions

If one of the above mentioned checks create a problem, do not use the WALL-MAN. Any defects must be reported immediately.

Weekly checks

Check air cylinder piston rod 1. Raise the cage to its upper position.

2. Clean the air cylinder piston rod with solvent and lubricate with engine oil.

Check brake system 1. Check for proper function of brake.

2. Check brake bands for wear.

3. Adjust flow restrictor if necessary.

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Always wear safety clothes, mask and/or glasses when working with solvents and/or oil.

Before starting the maintenance work, lower the cage and disconnect WALL-MAN from

compressed air.

In case of defects or malfunctions, see also section 7.2 Trouble shooting.


Weekly checks

Check all air connections 1. Listen to all connections. Possible leaks must be located and rectified. See also section 7.1.1.

Check the chain slack control device

1. Place a solid piece of wood on the ground below the cage.

Ensure that the timber is placed in a position that prevents it from breaking or causing damage.

2. Using the centre lever on the control panel or the emergency lowering lever on the mast, lower the cage onto the piece of wood.

When lowering with the centre lever do not enter the cage.

3. If the slack chain control device works correctly, the chains remain tight.

4. If the chain is slack, check/adjust the device.

5. Grease the activator on the chain-slack control if the device is dry.

Check the rail pivots(if applicable)

1. Operate the pivot.

2. Verify that it opens/closes easily.

3. Verify the guide rail locks engage/disengage correctly.

Check door 1. Verify that the door opens and closes easily.If required tighten door spring.

2. Verify that the latch works correctly.

Every 6 months

Check all screw connections, chains and welds.

1. Check all wheels, rollers and shafts. Replace in case of heavy wear.

2. Check screws, nuts and bolts. Tighten if necessary.

3. Check the chains for wear.

4. Double check the chain fastenings.

5. Check all rail fixing points on wall and rubber end stoppers for wear and damage.

6. Check all welds for cracks, especially at rail pivots.

Lubrication of the lifting cylinders.

1. Switch off air supply.

2. Pull the upper supply hose from the cylinder and vent the cylinder

3. Fill 2 squirts of SAE 10-30 engine oil in each cylinder.

4. Refit the upper supply hose.

5. Turn air supply back on.

6. Raise and lower the cage several times to distribute the oil equally.

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7.1.1 Handling leaks

Air leaks appear most often at connectors, hose connections or inside pneumatic components.

This causes a sound which can be heard.

To verify the leak use soapy water as follows:

1. Apply a thin film of soapy water where the leak is suspected.

2. Escaping air creates bubbles and indicates the location of the leak.

This method can also be used to find leaks on cylinder seals.

3. When finished, dry off remaining soap and water.

Hoses and connections can also cause leaks.

Hoses must not be bent too much.

Hoses must be properly fitted to the connectors.

If there is a leak at a connector, disconnect the hose and check that the hose end is cut straight and not deformed.

Valves with leaks must be replaced with Norgren parts only.

7.1.2 Measuring air pressure

1. Before applying compressed air, insert a T-joint to where the pressure is to be measured.

2. Connect the gauge with hose and connector to this T-joint.

3. Check for proper fit, apply compressed air and measure.

4. When measuring is complete, remove T-joint.

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7.2 TROUBLE SHOOTING

Fault Cause Solution Remarks

Nothing works or only slow movements

Low air pressure Adjust air pressure Refer to section 2.1 for maximum pressure (disconnect air supply)Air leak Tighten the leak

Defective cylinder / motor / valve

Change defective parts

Bent air hose Straighten air hose

No vertical movement of the cage

Overload Reduce load Refer to section 2.1 for maximum payload

Low air pressure Adjust pressure Refer to section 2.1 for maximum pressure (disconnect air supply)

Defective control valve Change defective parts

Sluggish lifting / lowering

Insufficient lubrication on the mast

Clean and lubricate the mast, especially the edges.

Use Vaseline or other silicone free grease.

No or sluggish sideways movement

Low air pressure Adjust pressure Refer to section 2.1 for maximum pressure

Obstacle or debris in the rails

Clean the rails

Air motor loose or disengaged

Check air motor Exact and careful cleaning.(disconnect air supply)

Defective control valve Change defective parts

(disconnect air supply)

No in / out movement

Low air pressure Adjust air pressure Refer to section 2.1 for maximum pressure

Sluggish in / out movement

Insufficient lubrication on in / out rails

Clean and lubricate in / out rails


Moves by itself Defective control valve Change defective parts


Slack-chain device out of position

Adjust parts

Air leak Tighten the leak

Air hoses do not rewind on reels

Ratchet on Release ratchet See manufacturer’s instructions.

Sticky hoses Apply talc or similar to hoses

Worn hoses Change air hoses

Defective reel Change reels

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7.3 REPLACEMENTS AND ADJUSTMENTS

7.3.1 Replacing the nylon rollers (WM-IO8 / WM-UD17)

The nylon rollers are spare parts that may have to be replaced after being used for a long time. They may also occasionally be damaged. The rollers can be replaced easily, once they have been unloaded by lowering the cage onto firm support.

1. Unscrew the lock nut on one end of the roller axle. 2. Unscrew the end cap and pull out the axle. 3. Reverse the procedure to replace with a new roller.

If the movement up and down is hesitant, especially on a new installation, a smear of Vaseline on the vertical mast especially at the corners will usually rectify the problem.

Do not use silicone or grease.

7.3.2 Replacement of the air motor

To replace the Atlas Copco air motor perform the following steps:1. Loosen the PC counter nuts 13 mm as well as 2 pc set screw with a 4mm hex key.2. Disconnect the air hoses and pull the motor straight out.3. Heat the drive shaft with a hot air gun to approx. 200 degrees C and pull it from the motor shaft.4. Clean the hole in the drive shaft, apply a couple of drops of LockTite 638 and place it on

the new motor shaft.

The set screws have to hit the plain part of the motor house.

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7.3.3 Adjustment of spring tension of the hose reels

To adjust the tension of the Nederman hose reels 893/889 and 884 perform the following steps:

Model 893/889 Model 884

1. Place the handle (1) (provided by Nederman) in the reel

2. Loosen and remove the bolts (2).3. Increase spring tension by moving the

handle counter clockwise.4. Decrease tension by moving the handle

clockwise.5. Refit the bolts and remove the handle.

Check that the required length of hose can be unreeled without stretching the spring to its limit.

1. Recoil the hose until the hose stops against the outlet. Pull the hose out, to a position where the ratchet is engaged. Unscrew hose stop and tool connected to the hose.

2. Turn the drum, with all the hose wound on: one revolution in the direction of the red arrow when increasing the spring tension; one revolution in the direction of the blue arrow when decreasing the tension.

3. Beat hose stop and tool.Check that the required length of hose can be unreeled without stretching the spring to its limit

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110916 reglo wall-man technical manual rev 7_layoutrev_28 04

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